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WO2001096814A2 - Systeme et procede de numerisation de donnees analogiques - Google Patents

Systeme et procede de numerisation de donnees analogiques Download PDF

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Publication number
WO2001096814A2
WO2001096814A2 PCT/US2001/016650 US0116650W WO0196814A2 WO 2001096814 A2 WO2001096814 A2 WO 2001096814A2 US 0116650 W US0116650 W US 0116650W WO 0196814 A2 WO0196814 A2 WO 0196814A2
Authority
WO
WIPO (PCT)
Prior art keywords
image
feature
camera
measuring instrument
measuring
Prior art date
Application number
PCT/US2001/016650
Other languages
English (en)
Other versions
WO2001096814A3 (fr
Inventor
Woo Sik Yoo
Kitaek Kang
Taro Yamazaki
Original Assignee
Wafermasters Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wafermasters Incorporated filed Critical Wafermasters Incorporated
Publication of WO2001096814A2 publication Critical patent/WO2001096814A2/fr
Publication of WO2001096814A3 publication Critical patent/WO2001096814A3/fr

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
    • G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
    • G01D5/26—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light
    • G01D5/39—Scanning a visible indication of the measured value and reproducing this indication at the remote place, e.g. on the screen of a cathode ray tube

Definitions

  • the present invention generally relates to a data conversion system and method, and more particularly, to a system and method for converting analog data to digital data using visual images.
  • a mass flow controller for example, is a well-known instrument used to maintain a preselected mass flow rate.
  • a typical mass flow controller operates on the principle of adding heat energy to a flowing fluid and measuring a heat transfer function and or thermal mass transport function in two sensors spaced in or near the flowing fluid.
  • the measure of the temperature difference between the sensors is a function of fluid mass flow.
  • the resistivity of the downstream second sensor is changed, the measured temperature difference between the sensors being the measure of flow.
  • the rise in temperature is a function of the amount of heat added, the sensor geometry and conductivity, the mass flow rate and the properties of the gas .
  • FIG. 1 an example of a typical mass flow controller 10 is shown, which includes a horizontal bypass sensor tube 12 with upstream and downstream sensors 14 and 16, respectively, exterior of the tube and a heater element 18 similarly wound between sensors 14 and 16 on the tube exterior.
  • a typical mass flow controller 10 which includes a horizontal bypass sensor tube 12 with upstream and downstream sensors 14 and 16, respectively, exterior of the tube and a heater element 18 similarly wound between sensors 14 and 16 on the tube exterior.
  • fluid liquid or gas
  • Each sensor 14 and 16 form part of a bridge and amplifier circuit, which can detect the temperature difference caused by the greater heat input to the downstream sensor 16, and can produce a signal proportional to the gas flow rate.
  • the flow rate signal is compared to a command voltage from a potentiometer or the like, which generates an error signal.
  • the error signal causes a valve to change the flow rate until a predetermined flow rate has been reached.
  • the mass flow controller has several drawbacks.
  • heat conduction is through the tube wall, which may result in relatively long response times.
  • this type of mass flow controller generally requires heating of the fluid up to about 100°-200° C greater than the ambient temperature of the incoming fluid. In many gaseous applications, this may be above the safe temperature limit of the gas or cause decomposition of the gas or reaction with contaminants.
  • the heater element requires greater amounts of power. Further, for each gas composition and flow range, the instrument must be calibrated because of nonlinearities and inconsistent correction factors.
  • the system and method should include the ability to convert analog data obtained from various meters and gages, to a digital data signal useable for operating various control devices.
  • the present invention provides an improved system and method for obtaining data related to the operation of a processing system, such as a semiconductor processing system.
  • a processing system such as a semiconductor processing system.
  • the present invention provides conversion from analog measurement data, usually obtained from meters and gages, to digital data, which is typically more useful for operating various control devices.
  • the present invention provides a system for collecting visual images of various types of measuring instruments, which are used for measuring a process functionality, such as mass flow rate, temperature, pressure, and the like.
  • An image sensor is included in the system for providing an image of a first feature of the measuring instrument.
  • the image data is processed by an image processor, which is operable to detect the first feature and determine its position relative to a second feature of the measuring instrument, which is the measured value.
  • the measured value can then be compared to a predetermined or expected value. If the measured and expected values are not substantially the same (within an acceptable limit) , a signal can be generated which instructs a controller to adjust the process functionality until the measured value reaches the expected value.
  • the present invention compares digitally formatted data rather than, for example, temperature differences (see Fig. 1) and is therefore less complex to implement, less costly to put into practice, and more reliable then typical mass flow controllers.
  • the present invention may provide uninterrupted measurement using readily available and easily implemented conventional measuring instruments.
  • the application of the present invention is flexible in that the invention can be used to monitor measuring instruments that currently exist on processing systems without having to change out the instruments .
  • Other uses, advantages, and variations of the present invention will be apparent to one of ordinary skill in the art upon reading this disclosure and accompanying drawings ..
  • FIG. 1 is a simplified illustration of a typical mass flow controller
  • FIG. 2 is a simplified diagram of a data collecting system in accordance with an embodiment of the present invention
  • FIGS. 3A-3B are simplified illustrations of embodiments of a measuring device in accordance with the present invention
  • FIG. 4 is a flow diagram of the operation of the present invention.
  • FIGS. 5A-5C are simplified illustrations of images in accordance with the present invention.
  • the present invention provides a system and associated method for collecting analog measurement data and converting the data to digital data for use with various control mechanisms.
  • the invention may be used with a variety of applications including the manufacturing process of semiconductor devices, hard disks, and liquid crystal displays.
  • the invention can be used with etching, deposition, chemical-mechanical planarization, and rapid thermal processing systems.
  • FIG. 2 is a simplified diagram of a data collection system 100 in accordance with an embodiment of the present invention.
  • Data collection system 100 may include a measuring instrument 102 or, alternatively a plurality of measuring instruments (not shown) , which are used to verify the operating conditions of a processing system.
  • System 100 also includes an image sensor 104, an image processor 106, a controller 108, and a control mechanism 110.
  • Measuring instrument 102 may be any device used to determine the value or magnitude ' of a quantity or variable. Of interest, are those quantities or variables that help to define or describe an object, a system, or a process. For example, in an industrial process, specifically a semiconductor manufacturing process, measurement and control of variables, such as temperature, pressure, time, velocity, and flow rate, determine quality and efficiency of production.
  • Measuring instrument 102 may include, but is not limited to any instrument which " can provide a real-time viewing capability, such as a thermometer, a manometer, a barometer, a dial gage, and a flow meter.
  • measuring instrument 102 can have a liquid crystal display (LCD) , which gives an alphanumeric indication of the value of a quantity or variable .
  • LCD liquid crystal display
  • measuring instrument 102 includes a minimum value indicator 112, a maximum value indicator 114, and a present value indicator 116 (e.g. a metering float in a flow meter) .
  • Each indicator 112, 114, and 116 is a feature that can be imaged by image sensor 104. Accordingly, features 112,114 and 116 must provide contrast, such that its location or position can be determined relative to the location or position of each other feature 112,114 and 116.
  • measuring instrument 102 includes lines or calibrations (i.e. features 112 and 114) drawn, etched or formed on instrument 102 at specific locations, which represent a particular value.
  • FIG. 3A illustrates one embodiment of . measuring instrument 102, which is a mass flow meter.
  • a substance liquid or gas
  • present value indicator 116 to rise (or fall) between minimum indicator 112 and maximum indicator 114.
  • FIG. 3B illustrates an embodiment in which measuring instrument 102 is a dial gage, such as a well-known
  • Bourdon-tube gage The dial gage operates in a well-known fashion to convert linear into rotary motion to move a pointer over a calibrated scale. As before, by action of pressure P flowing through tube 120, present value indicator 116 can be made to rotate between minimum indicator 112 and maximum indicator 11 .
  • FIG. 3C illustrates an embodiment in which measuring instrument 102 is a thermometer. Again, applying well known volumetric flow science, by action of the temperature of a substance flowing through tube 120, present value indicator 116 can rise (or fall) between minimum indicator 112 and maximum indicator 114.
  • image sensor 104 may be mounted near measuring instrument 102 using conventional mounting techniques.
  • the conventional mounting allows for precision positioning of image sensor 104.
  • image sensor 104 can be positioned with a view angle ⁇ relative to a line of sight axis 130 of between 0°
  • the image of measuring instrument 102 acquired by image sensor 104 is used to provide the position of present level indicator 116 between minimum indicator 112 and maximum indicator 114.
  • image sensor 104 may be any conventional camera, such as a CCD camera, a video camera, a photographic camera, or a digital camera, which can record an image of a target object as digital image data upon a recording medium such as a memory card.
  • camera 104 may be a QUICKCAMTM Home camera from Logitech Corporation of Fremont, California.
  • image processor 106 provides digitized image output, which can be provided to image processor 106 via a Universal Serial Bus (“USB”) (not shown) .
  • USB Universal Serial Bus
  • the image acquired using a non- digital camera 104 is first digitized using a conventional digitizer before the image is processed in image processor 106.
  • the output signals from camera 104 are applied as input to image processor 106 for use in computing the relative position of indicators 112, 114, and 116.
  • controller 108 controls the operation of control mechanism 110, which may include drive motors, valves, solenoids, actuators, and the like.
  • Control mechanism 110 enables the adjustment of the processing functionality being monitored (e.g. mass flow, temperature, pressure, and the like) . Details of the control circuitry are conventional and can be readily tailored by those of usual skill in the art to a particular function.
  • FIG'. 4 is a flow diagram 200 of the process using the system of the present invention.
  • the operation of the present invention begins by acquiring an image (202) of measuring instrument 102.
  • Image 202 Light from measuring instrument 102 is focused by a photographic lens upon a photoelectric conversion element in an imaging section.
  • Analog image data which is photoelectrically converted by the photoelectric conversion element, is converted into digital data by an A/D conversion device.
  • Various forms of signal processing are performed upon this digital image data, and the data is then temporarily stored in a buffer memory.
  • the digitized image output signals from image sensor 104 may be stored as a bitmap.
  • Bitmaps are known in the art. Generally, a bitmap can be thought of as an array of pixels, each pixel representing a point on the digitized image. By knowing the resolution of the bitmap, the number of pixels in each row and the number of pixels in each column of the bitmap are also known. For example, a 640 x 480 bitmap has 480 rows and 640 columns of pixels. Each pixel in a selected column is extracted and converted to units of red, green, and blue (“RGB”) intensity or normal gray scale intensity. The resulting intensity values of all pixels in the selected column can be loaded into a spreadsheet or application program for processing. The invention can be performed using any pixel or image format.
  • each pixel in the selected column can also be converted to the so-called HSV format .
  • the digital image data is directed to image processor 106 for image processing (204) .
  • Image processor 106 receives the digital image data to perform a well-known digital image processing technique, such as those described generally in R. Gonzal.es and R. Woods, “Digital Image Processing”, Addison-Wesley Publishing Co., 1993, pgs. 518-560, and as generally described in G. Baxes, "Digital Image Processing: Principles and Applications,” Wiley and Sons, Inc. 1994, which are herein incorporated by reference for all purposes .
  • the image processing techniques extract image components that are useful in the representation and description of shape boundaries and the like, and are used herein to detect indicators 112, 114, and 116.
  • each indicator is a boundary between two regions with relatively distinct gray-level properties.
  • the indicator is detected by distinguishing discontinuities in the gray-level where the transition between two regions occurs .
  • a map can be created from the detection of the line.
  • the map is an intrinsic image, which contains the likelihood that a pixel belongs to an indicator line.
  • a small neighborhood of pixels such as a 3 x 3 or 5 x 5 array of pixels, is analyzed. All points that are similar are linked forming a boundary of pixels that share common properties, such as strength and direction.
  • the gradient is defined as:
  • T is a nonnegative threshold.
  • the direction of the gradient vector is given by:
  • image processor 106 can use well-known mathematical relationships to estimate the relative distance between minimum level indicator 112 and present level indicator
  • present level indicator 116 may be a metering float or other device, which has a thickness greater than a single line (see FIG. 5A) .
  • image processor 106 can detect a first edge 132 and a second edge 134 using the technique described above. Once these edges are known the distance between them D 3 can be calculated. By dividing this distance in half, the center of the indicator can be determined for use in calculating distances D x and D 2 .
  • the distances are compared to a preselected reference distance to determine whether the system requires adjustment (206) . If the measured distance is different from the reference distance beyond a predetermined limit, the image processor generates a signal (208) .
  • the signal is a direction, which is sent to controller 108.
  • Controller 108 receives the signal, which instructs controller 108 to perform a function. For example, using the mass flow meter embodiment of FIG. 3A, if it is found that the distance between present level indicator 116 and minimum level indicator 112 is too low, controller 108 is instructed to direct valve mechanism 110 to increase the flow rate. As soon as the distance between indicator 112 and 116 is within a predetermined range, controller 108 is instructed to adjust valve 110 accordingly.
  • indicators 112, 114, and 116 may be found on the image of a dial gage (see FIG. 3B) .
  • image processor 106 can use well-known mathematical relationships to estimate the relative angle between minimum level indicator 112 and present level indicator 116, referenced as ⁇ x .
  • the relative angle between maximum level indicator 114 and present level indicator 116, referenced as ⁇ 2 can also be
  • the values are compared to a preselected reference value, which corresponds to a desired operational value, to determine whether the system requires adjustment. If the measured angle is different from the reference angle beyond a predetermined limit, the image processor generates a signal. The signal is a direction, which is sent to controller 108. Controller 108 receives the signal, which instructs controller 108 to perform a , function. For example, using the pressure meter embodiment of FIG. 3B, if it is found that the angle between present level indicator 116 and minimum level indicator 112 is too shallow, controller 108 is instructed to direct pressure regulator 110 to increase the pressure to the system.
  • indicators 112, 114, and 116 may be found on the image of a thermometer (see FIG. 3C) .
  • the thermometer presents a column shaped indicator 140, which has a leading edge 142 that defines present level indicator 116.
  • image processor 106 can use well-known mathematical relationships to estimate the relative distance between minimum level indicator 112 and present level indicator 116, referenced as Fi.
  • the relative distance between maximum level indicator 114 and present level indicator 116, referenced as F 2 can be determined.
  • the values are compared to a preselected reference value, which corresponds to a desired operational temperature, to determine whether the system requires adjustment. If the measured distances Fi and/or F 2 are different from the reference value beyond a predetermined limit, the image processor generates a signal. The signal is a direction, which is sent to controller 108. Controller 108 receives the signal, which instructs controller 108 to perform a function. For example, using the thermometer embodiment of FIG. 3C, if it is found that the distance between present level indicator 116 and minimum level indicator 112 is too large, controller 108 is instructed to direct temperature regulator 110 to decrease the temperature to the system. As soon as the distance between indicator 112 and 116 is back within a predetermined range, the controller is instructed to adjust temperature regulator 110 accordingly to maintain the proper temperature in the system.
  • Flow meters, pressure gages, thermometers, as well as other types of measuring instruments may have additional calibrations or other extraneous features, other than the minimum, maximum, and present level indicators. To reduce confusion that may occur as to the proper reference point to be used in the image processing calculations described above, these calibrations and extraneous features should be ignored. Accordingly, an initial calibration image can be made of the desired measuring instrument . Features that are to be used in calculating the measured values are selected, while the remaining features are ignored. Thus, during operation of the present invention, the non-desired features can be filtered from the image .
  • the description of the invention given above is provided for purposes of illustration and is not intended to be limiting. The invention is set forth in the following claims.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Measuring Volume Flow (AREA)
  • Testing Or Calibration Of Command Recording Devices (AREA)
  • Arrangements For Transmission Of Measured Signals (AREA)

Abstract

L'invention concerne un système et un procédé améliorés d'obtention de données, liées à la mise en oeuvre d'un système de traitement qui convertit des données de mesure analogiques, habituellement obtenues à partir d'appareils de mesure et de jauges, en données numériques. Des images visuelles de différents types d' instruments de mesure sont recueillies et utilisées pour mesurer la fonctionnalité d'un traitement. Un capteur d'image fournit une image d'une première caractéristique de l'instrument de mesure. Les données de l'image sont traitées par un processeur d'images, qui est utilisable pour détecter une première caractéristique et déterminer sa position par rapport à une seconde caractéristique de l'instrument de mesure. La différence entre ces positions relatives (distance mesurée) peut ensuite être comparée à une valeur prédéterminée ou prévue. Si ces valeurs mesurées et prévues ne sont pas sensiblement identiques, un signal peut être généré donnant la consigne à un contrôleur de régler la fonctionnalité du traitement jusqu'à ce que la valeur mesurée soit égale à la valeur prévue.
PCT/US2001/016650 2000-06-08 2001-05-22 Systeme et procede de numerisation de donnees analogiques WO2001096814A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/590,714 2000-06-08
US09/590,714 US6621943B1 (en) 2000-06-08 2000-06-08 System and method for converting analog data to digital data

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WO2001096814A2 true WO2001096814A2 (fr) 2001-12-20
WO2001096814A3 WO2001096814A3 (fr) 2002-06-27

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TW (1) TW514718B (fr)
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Cited By (1)

* Cited by examiner, † Cited by third party
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EP2905595A1 (fr) * 2014-02-11 2015-08-12 Baumer Bourdon-Haenni SA Dispositif de test de jauge

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EP1177411A1 (fr) * 1999-05-10 2002-02-06 Schröter, Michael Compteur de consommation et procede pour relever un compteur de consommation fixe
GB0024612D0 (en) * 2000-10-07 2000-11-22 Bg Intellectual Pty Ltd Utility meter index plate data reading
US20030076241A1 (en) * 2001-10-23 2003-04-24 Middleton Frazer Neil Apparatus and method of remote monitoring of utility usage
CA2603797A1 (fr) * 2005-04-04 2006-10-12 Eric A. Carlson Support lisible par machine, procede et systeme de mesure lineaire
CA2655591A1 (fr) * 2009-02-17 2010-08-17 Wisemen Controls & Instrumentation Ltd. Lecteur de debitmetre de gaz
US20160356725A1 (en) * 2014-02-04 2016-12-08 Nsk Americas, Inc. Apparatus and method for inspection of a mid-length supported steering column assembly
TWI579664B (zh) * 2015-12-14 2017-04-21 仁寶電腦工業股份有限公司 校準手錶之方法
EP4058630A4 (fr) * 2019-11-14 2023-11-29 Buckman Laboratories International, Inc. Système et procédé de commande prédictive pour un traitement de lavage brun dans des usines de pâte à papier

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FR2611067B1 (fr) 1987-02-18 1989-09-15 Izard Pierre Procedes et dispositifs pour relever a distance des indicateurs numeriques, notamment ceux qui equipent des compteurs
US4837708A (en) * 1987-07-01 1989-06-06 Maraven, S.A. Process and apparatus for determining flow rate of a flow medium in a flow line
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US5673331A (en) 1995-06-03 1997-09-30 United States Department Of Energy Method and apparatus for reading meters from a video image
JP3435288B2 (ja) * 1996-06-20 2003-08-11 ペンタックス株式会社 カメラシステム

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2905595A1 (fr) * 2014-02-11 2015-08-12 Baumer Bourdon-Haenni SA Dispositif de test de jauge

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WO2001096814A3 (fr) 2002-06-27
TW514718B (en) 2002-12-21
US6621943B1 (en) 2003-09-16

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